Multi-piece vehicle wheel cover retention system and method for producing same

Abstract

A method for producing a multi-piece vehicle wheel retention system comprising the steps of: (a) providing a wheel having a wheel disc defining and axis and an outboard facing wheel surface and including an outboard tire bead seat retaining flange; (b) providing a first outer wheel cover formed from a first material, the first outer wheel cover covering at least a portion of outboard tire bead seat retaining flange of the wheel disc; (c) providing a second inner wheel cover formed from a second material, the second inner wheel cover covering at least a substantial portion of the outboard facing wheel surface of the wheel disc, the second wheel cover including an outboard surface and an inboard surface; (d) securing the first outer wheel cover and the second inner wheel cover together by at least an interference fit therewith; and (e) non-permanently securing the assembled wheel covers of step (d) and the wheel to one another by a non-permanent mechanical attachment feature to produce the multi-piece vehicle wheel retention system.

What is claimed is: 
     
       1. A method for producing a multi-piece vehicle wheel cover retention system comprising the steps of:
 (a) providing a wheel having a wheel disc defining and axis and an outboard facing wheel surface and including an outboard tire bead seat retaining flange; 
 (b) providing a first outer wheel cover formed from a first material, the first outer wheel cover covering at least a portion of outboard tire bead seat retaining flange of the wheel disc; 
 (c) providing a second inner wheel cover formed from a second material, the second inner wheel cover covering at least a substantial portion of the outboard facing wheel surface of the wheel disc, the second wheel cover including an outboard surface and an inboard surface; 
 (d) providing an insert formed from a third material and which generally corresponds to at least the shape of a space formed between the outboard facing wheel surface of the wheel and the inboard surface of the second wheel cover, the insert including an outboard surface and an inboard surface; 
 (e) securing the first outer wheel cover and the second inner wheel cover together by at least an interference fit therewith; and 
 (f) non-permanently securing the assembled wheel covers of step (e), the insert and the wheel to one another by a non-permanent mechanical attachment feature to produce the multi-piece vehicle wheel retention system. 
 
     
     
       2. The method of  claim 1  wherein the first outer wheel cover includes a generally U-shaped outer end, a first leg which extends generally parallel with respect to the axis, and a second leg which extends generally perpendicular to the first leg, and wherein at least a portion of the second leg of the first outer wheel cover extends behind the second inner wheel cover so as to be adjacent the inboard surface of the second inner wheel cover and wherein the at least a portion of the second leg of the first outer wheel cover is at least secured to the second wheel cover by the at least a portion of the second leg being disposed within a surface feature provided only on the inboard surface of the second inner wheel cover to thereby secure the first outer wheel cover and the second inner wheel cover together in the interference fit therewith. 
     
     
       3. The method of  claim 2  wherein step (e) includes applying an adhesive on at least one of the inboard surface of the second inner wheel cover and an outboard surface of the first wheel cover in the area of the surface feature to permanently secure the first outer wheel cover to the second inner wheel cover. 
     
     
       4. The method of  claim 1  wherein the second inner wheel cover is provided with at least one surface feature provided thereon which provides the non-permanent mechanical attachment feature for non-permanently securing the assembled wheel covers and the insert to the wheel. 
     
     
       5. The method of  claim 4  wherein the at least one surface feature is an axially extending post provided on an inboard surface of the second inner wheel cover which is adapted to extend through an opening provided in the wheel. 
     
     
       6. The method of  claim 5  wherein the post includes one of a push-in type of end and a push-on type of end. 
     
     
       7. The method of  claim 1  wherein the second inner wheel cover is provided with a center hub hole and a plurality of windows formed therein between each of a pair spokes, and wherein a plurality of surface features are provided thereon which provide the non-permanent mechanical attachment for non-permanently securing the assembled wheel covers and the insert to the wheel. 
     
     
       8. The method of  claim 7  wherein the plurality of surface features are provided thereon in an area adjacent the center hub hole. 
     
     
       9. The method of  claim 7  wherein the second inner wheel cover includes a plurality of lug bolt openings, and wherein a respective one of the plurality of surface features is provided between each pair of the lug bolt openings. 
     
     
       10. The method of  claim 7  wherein of a respective one of the plurality of surface features is provided between each pair of the windows. 
     
     
       11. The method of  claim 7  wherein the second inner wheel cover includes a plurality of lug bolt openings, and wherein the said plurality of surface features of said second inner wheel cover include a first plurality of surface features and a second plurality of surface features, a respective one of the first plurality of surface features provided between each pair of the lug bolt openings and a respective one of the second plurality of surface features is provided between each pair of the windows. 
     
     
       12. The method of  claim 1  wherein the first outer wheel cover is formed from a metal material, the second inner wheel cover is formed from a plastic material, and the insert is formed from a foam material. 
     
     
       13. A method for producing a multi-piece vehicle wheel cover retention system comprising the steps of:
 (a) providing a wheel having a wheel disc defining and axis and an outboard facing wheel surface and including an outboard tire bead seat retaining flange; 
 (b) providing a first outer wheel cover formed from a first material, the first outer wheel cover covering at least a portion of outboard tire bead seat retaining flange of the wheel disc; 
 (c) providing a second inner wheel cover formed from a second material, the second inner wheel cover covering at least a substantial portion of the outboard facing wheel surface of the wheel disc, the second wheel cover including an outboard surface and an inboard surface; 
 (d) securing the first outer wheel cover and the second inner wheel cover together by at least an interference fit therewith; and 
 (e) non-permanently securing the assembled wheel covers of step (d) and the wheel to one another by a non-permanent mechanical attachment feature to produce the multi-piece vehicle wheel retention system, wherein the second inner wheel cover is provided with at least one surface feature provided thereon which provides the non-permanent mechanical attachment feature for non-permanently securing the assembled wheel covers to the wheel. 
 
     
     
       14. The method of  claim 13  wherein the first outer wheel cover includes a generally U-shaped outer end, a first leg which extends generally parallel with respect to the axis, and a second leg which extends generally perpendicular to the first leg, and wherein at least a portion of the second leg of the first outer wheel cover extends behind the second inner wheel cover so as to be adjacent the inboard surface of the second inner wheel cover and wherein the at least a portion of the second leg of the first outer wheel cover is at least secured to the second wheel cover by the at least a portion of the second leg being disposed within a surface feature provided only on the inboard surface of the second inner wheel cover to thereby secure the first outer wheel cover and the second inner wheel cover together in the interference fit therewith. 
     
     
       15. The method of  claim 13  wherein step (d) includes applying an adhesive on at least one of the inboard surface of the second inner wheel cover and an outboard surface of the first wheel cover in the area of the at least one surface feature to permanently secure the first outer wheel cover to the second inner wheel cover. 
     
     
       16. The method of  claim 13  wherein the at least one surface feature is a an axially extending post provided on an inboard surface of the second inner wheel cover which is adapted to extend through an opening provided in the wheel. 
     
     
       17. The method of  claim 16  wherein the post includes one of a push-in type of end and a push-on type of end. 
     
     
       18. The method of  claim 13  wherein the second inner wheel cover is provided with a center hub hole and a plurality of windows formed therein between each of a pair spokes, and wherein a plurality of surface features are provided thereon which provide the non-permanent mechanical attachment for non-permanently securing the assembled wheel covers to the wheel. 
     
     
       19. The method of  claim 18  wherein the plurality of surface features are provided thereon in an area adjacent the center hub hole. 
     
     
       20. The method of  claim 18  wherein the second inner wheel cover includes a plurality of lug bolt openings, and wherein a respective one of the plurality of surface features is provided between each pair of the lug bolt openings. 
     
     
       21. The method of  claim 18  wherein of a respective one of the plurality of surface features is provided between each pair of the windows. 
     
     
       22. The method of  claim 18  wherein the second inner wheel cover includes a plurality of lug bolt openings, and wherein the second inner wheel cover is provided with a first plurality of surface features and a second plurality of surface features provided therein, a respective one of the first plurality of surface features provided between each pair of the lug bolt openings and a respective one of the second plurality of surface features is provided between each pair of the windows. 
     
     
       23. The method of  claim 13  wherein the first wheel cover is formed from a metal material and the second wheel cover is formed from a plastic material. 
     
     
       24. A multi-piece vehicle wheel cover retention system comprising:
 a wheel having a wheel disc defining and axis and an outboard facing wheel surface and including an outboard tire bead seat retaining flange; 
 a first outer wheel cover formed from a first material, the first outer wheel cover covering at least a portion of outboard tire bead seat retaining flange of the wheel disc; and 
 a second inner wheel cover formed from a second material, the second inner wheel cover covering at least a substantial portion of the outboard facing wheel surface of the wheel disc, the second wheel cover including an outboard surface and an inboard surface; 
 wherein the first outer wheel cover and the second inner wheel cover are attached together by at least an interference fit therewith to produce an assembled wheel cover assembly; and 
 wherein the assembled wheel cover assembly is non-permanently secured to the wheel by a non-permanent mechanical attachment feature to produce the multi-piece vehicle wheel retention system; 
 wherein the second inner wheel cover is provided with at least one surface feature provided thereon which provides the non-permanent mechanical attachment feature for non-permanently securing the assembled wheel covers to the wheel. 
 
     
     
       25. The multi-piece vehicle wheel cover retention system of  claim 24  wherein the first outer wheel cover includes a generally U-shaped outer end, a first leg which extends generally parallel with respect to the axis, and a second leg which extends generally perpendicular to the first leg, and wherein at least a portion of the second leg of the first outer wheel cover extends behind the second inner wheel cover so as to be adjacent the inboard surface of the second inner wheel cover and wherein the at least a portion of the second leg of the first outer wheel cover is at least secured to the second wheel cover by the at least a portion of the second leg being disposed within a surface feature provided only on the inboard surface of the second inner wheel cover to thereby secure the first outer wheel cover and the second inner wheel cover together in the interference fit therewith. 
     
     
       26. The multi-piece vehicle wheel cover retention system of  claim 24  wherein the at least one surface feature is a an axially extending post provided on an inboard surface of the second inner wheel cover which is adapted to extend through an opening provided in the wheel.